Form having abutting tape-interconnected substrates and method of making same

ABSTRACT

A business form product ( 10 ) broadly including a printable sheet ( 12 ), a magnetic sheet ( 14 ) aligned edge-to-edge with the printable sheet ( 12 ) to define a seam ( 16 ), and a heat-resistant tape ( 18 ) applied over the seam ( 16 ) to retain the sheets ( 12,14 ) in the edge-to-edge relationship is disclosed. The inventive business form product ( 10, 106 ) is formed by joining multiple continuous webs ( 38, 58 ) edge-to-edge and marrying the webs ( 38,58 ) with a continuous streamer of tape ( 86 ) in a press ( 36 ). A preferred embodiment of the inventive method of forming the continuous sheet ( 106 ) is disclosed wherein at least one rotatable mechanical web guide ( 72 ) is used to align the webs ( 38,58 ) in the edge-to-edge relationship, thereby enabling precise alignment not available with existing optic-type web guides. A preferred embodiment of the printable business form product ( 10 ) is disclosed wherein heat-resistant tape ( 18 ) enables the business form product ( 10 ) to be printed in high-heat printing applications (e.g., printed in an offline laser printer) without fracturing the taped seam ( 16 ).

RELATED APPLICATIONS

The present application is a continuation application of Application forU.S. patent Ser. No. 11/379,122 entitled FORM HAVING ABUTTINGTAPE-INTERCONNECTED SUBSTRATES AND METHOD OF MAKING SAME, Filed Apr. 18,2006, which is a continuation of Application for U.S. patent Ser. No.10/248,570 entitled FORM HAVING ABUTTING TAPE-INTERCONNECTED SUBSTRATESAND METHOD OF MAKING SAME, filed Jan. 29, 2003, now U.S. Pat. No.7,029,001, which is a continuation-in-part application of Applicationfor U.S. patent Ser. No. 10/065,735 entitled DIE CUT SHEET WITH APPLIEDCOATING CARRIER, filed Nov. 13, 2002, now U.S. Pat. No. 6,773,181 (“the'735 Application”), all of which are hereby incorporated by referenceherein.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to printable forms formed in arotary press. More specifically, the present invention concerns acontinuous printable sheet, and individual printable forms sheetedtherefrom, wherein the continuous printable sheet is formed by joiningmultiple continuous webs edge-to-edge and marrying the webs with aheat-resistant ape. A preferred embodiment of the inventive method offorming the continuous sheet includes utilizing at least one rotatablemechanical web guide to align the webs, thereby enabling precisealignment not available with existing optic-type web guides. A preferredembodiment of the printable form includes a heat-resistant tape thatenables the form to be printed in high-heat printing applications (e.g.,printed in an offline laser printer) without fracturing the taped seam.

2. Discussion of Prior Art

It is desirable in many printing applications to join multiplecontinuous webs in a press to form a single continuous printable sheetthat can be printed, sheeted into forms before or after printing, etc.It is desirable to enable joining differing webs, for example, websformed of different materials (e.g., paper, magnetic material, etc.)and/or having differing thicknesses (e.g., one web having a single layerand one web having multiple layers, etc.). However, the continuousprintable sheet, and any individual form, or blank, formed therefrom, ispreferably adapted to be subsequently fed through any desired printingsystem (e.g., a downstream inline print station in a press, an offlinelaser printer, etc.). Accordingly, the multiple webs must besufficiently adhered together, or married, to enable the resulting sheetto withstand a subsequent printing operation. Adhesion applications haveproven difficult and ineffective when using certain types of substrates,and have prevented the utilization of certain types of printing systems.For example, when a relatively thick substrate is used in one of thewebs (e.g., a magnetic substrate, a plastic substrate, etc.) for joinderwith a relatively thin web (e.g., paper, etc.), the thicker web musttypically be overlain with the thinner web to provide the necessarystrength of the seam. The thickness of the adhesion seam is undesirableif the resulting blank cannot be fed into a desktop printer, such as alaser or ink jet printer.

It is known in the art to overlay the edges of continuous webs andadhere the webs together with a glue-type adhesive to form a singlecontinuous sheet. It is known in the art to utilize optic-type webguides to align the webs prior to joinder. One example of the prior artweb guides are available as special orders (e.g., configured for thespecific thickness and the width of the web as provided by the customer)from Coast Controls Inc. of Sarasota, Fla. It is also known in the artto utilize tape to retain die cut, removable sections in a continuoussheet or a blank, such as a card. These prior art joinder methods andprior art taping techniques are problematic and subject to severalundesirable limitations.

For example, the prior art joinder methods produce a thick seamincluding both substrates and the adhesive, wherein the adhesive maycomprise multiple layers. When one of the substrates is relatively thick(e.g., a magnetic or plastic substrate), the thick seams do not enablethe forms to be fed into a laser printer. Moreover, the thickness of theseam hinders or even prevents the forms from being stacked up, as isdesirable for offline printing applications. The prior art optic-typeweb guides used to align the substrates prior to joinder do not enablethe desired tolerances for edge-to-edge marrying. For example, prior artweb guides typically include a sensor that effects aligning movement ofan upstream roller. However, there is a necessary delay in sensing a webis out of alignment and the corrective realignment of the upstreamroller. This delay results in a see-saw type movement of the web, or a“loop.” Accordingly, prior art web guides are limited to alignmenttolerances of about one-thirty-seconds inch or at best one-sixty-fourthsinch. It is also known in the art to run the web over a stationaryobstruction (e.g., a piece of metal, etc.) in the web's path to effectalignment. However, this method of alignment causes large amounts offriction between the web and the obstruction, which results in heat,which in turn leads to undesired damage of the web.

The prior art taping techniques do not enable the form or blank to beprinted in some desirable printing systems. For example, it is becomingincreasingly more popular for end users to print forms or blanks intheir own desktop laser printers. However, these laser printers arerelatively high-heat printing stations that subject the forms totemperatures as high as 175 degrees Fahrenheit. The prior art tapingtechniques utilized tape that could not withstand the temperatures ofthe high-heat printing stations, i.e., the tape would lose its integrityand the seam would fracture.

SUMMARY OF THE INVENTION

The present invention provides a continuous printable sheet, andindividual printable forms sheeted therefrom, and a method of making thesame that do not suffer from the problems and limitations of the priorart joinder methods and taping techniques detailed above. The inventivecontinuous printable sheet is formed by joining multiple continuous websedge-to-edge and marrying the webs with a streamer of tape. A preferredembodiment of the inventive method of forming the continuous sheetincludes utilizing at least one rotatable mechanical web guide to alignthe webs, thereby enabling precise alignment not available with existingoptic-type web guides. A preferred embodiment of the printable formincludes a heat-resistant tape that enables the form to be printed inhigh-heat printing applications (e.g., printed in an offline laserprinter) without fracturing the taped seam.

A first aspect of the present invention concerns a method of forming abusiness form product of multiple substrates. The method includes thesteps of feeding a first continuous substrate web along a longitudinalpath, feeding a second continuous substrate web along the path, aligningthe first and second webs in an edge-to-edge relationship to form a seamtherebetween, wherein the seam extends along and is at least generallyparallel to the path, and applying a continuous streamer of tape to thewebs over and along the seam to retain the webs in said edge-to-edgerelationship to thereby form a common continuous sheet.

A second aspect of the present invention concerns a printable businessform product that comprises multiple substrates. The business formproduct is formed by a process including the steps of feeding a firstcontinuous substrate web along a longitudinal path, feeding a secondcontinuous substrate web along the path, aligning the first and secondwebs in an edge-to-edge relationship to form a seam therebetween,wherein the seam extends along and is at least generally parallel to thepath, and applying a continuous streamer of tape to the webs over andalong the seam to retain the webs in said edge-to-edge relationship tothereby form a common continuous sheet.

A third aspect of the present invention concerns a rotary press forjoining multiple continuous webs into a single continuous sheet. Thepress broadly includes a first unwinding station for feeding a first oneof the multiple continuous webs downstream, a second unwinding stationfor feeding a second one of the multiple continuous webs downstream, anda mechanical web guide including a shaft and at least one collarassociated with the shaft. The first unwinding station includes at leastone first idler roller and means for aligning the first web relative tothe first idler roller. The second unwinding station includes at leastone second idler roller and means for aligning the second web relativeto the second idler roller. The collar is operable to align the secondweb relative to the first web. At least a portion of the mechanical webguide is operable to engagingly receive the second web and is rotatablewhen the second web is engagingly received thereon.

A fourth aspect of the present invention concerns a printable blankbroadly including a first portion formed from a first web, a secondportion formed from a second web, and tape retaining the first andsecond portions together. The first portion is positioned in anedge-to-edge relationship with the second portion to define a seamtherebetween. The tape retains the first and second portions in theedge-to-edge relationship and is affixed to the first and secondportions overlying the seam. The tape is heat resistant.

Other aspects and advantages of the present invention will be apparentfrom the following detailed description of the preferred embodiments andthe accompanying drawing figures.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

Preferred embodiments of the invention are described in detail belowwith reference to the attached drawing figures, wherein:

FIG. 1 is a front elevational view of a business form productconstructed in accordance with a preferred embodiment of the presentinvention and including a bisectional, continuous printed surface formedfrom an upper paper section joined edge-to-edge with a lower magneticsection and adhered at the seam with a heat-resistant tape;

FIG. 2 is a rear elevational view of the business form productillustrated in FIG. 1 showing the heat-resistant tape over the seambetween the upper and lower sections;

FIG. 3 is a sectional view of the business form product takensubstantially along line 3-3 of FIG. 1 showing the seam between themultiple layers of the lower section and the upper section;

FIG. 4 is a schematic diagram of a rotary press for forming a businessform product of a preferred embodiment of the present invention andincluding a mechanical web guide for aligning one of the websedge-to-edge with the other web and a pair of mechanical tape guides foraligning the tape over the seam between the webs;

FIG. 5 is a bottom perspective view of the press illustrated in FIG. 4and showing the mechanical tape guides and the mechanical web guidefeeding the corresponding streamer of tape and web into the nip roller;

FIG. 6 is a sectional view of a business form product constructed inaccordance with a preferred alternative embodiment of the presentinvention and including multiple substrates joined edge-to-edge with astreamer of heat-resistant tape over the seam; and

FIG. 7 is a flow diagram depicting a method of forming a business formin accordance with a preferred embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1 illustrates a business form product 10 constructed in accordancewith the principles of a preferred embodiment of the present invention.As detailed below, the illustrated business form product 10 is formed byjoining two continuous webs edge-to-edge and joining the webs with astreamer of heat-resistant tape to form a continuous roll. However, itis within the ambit of the present invention to marry more than two websinto a single continuous sheet with the principles of the presentinvention. The illustrated business form product 10 is a form that hasbeen sheeted from the continuous roll and printed in an offline laserprinter. However, the principles of the present invention are notlimited to sheeted, printed forms and equally apply to other businessform products, which as will be defined below, includes the continuousroll, before or after printing. It is important, however, that thebusiness form product 10 is formed by the inventive method assubsequently described in detail. The illustrated business form product10 broadly includes a printable sheet 12, a magnetic sheet 14 alignededge-to-edge with the printable sheet 12 to define a seam 16, and aheat-resistant tape 18 applied over the seam 16 to retain the sheets12,14 in the edge-to-edge relationship.

The illustrated business form product 10 is a bisectional, generallyrectangular form presenting an upper section 20 and a lower section 22.As will be subsequently described in detail, the sections 20,22 arejoined to present a continuous printable surface 24. That is to say, theform 10 can be fed into a single printing system to print the entiresurface 24 in one application. The upper section 20 comprises theprintable sheet 12 and the lower section 22 comprises the magnetic sheet14, a coating carrier and a plurality of die cuts as will be described.

As shown in FIGS. 1-3, the illustrated printable sheet 12 includes a topprintable surface 26 and a bottom surface 28 opposite the surface 26.The printable surface 26 comprises the upper portion of the printablesurface 24. In the sheet 12, the printable surface 26 is illustrated onthe front face of the sheet 12, however, the bottom surface 28 is alsoprintable and either or both of the surfaces 26,28 could be printed. Theillustrated sheet 12 is preferably formed from a non-magnetic material,such as paper. The illustrated printable sheet 12 is a generallyrectangular sheet, such as sheeted to an eight-and-one-half inch widthfrom printable paper stock. However, the printable sheet 12 could beformed of virtually any printable material (e.g., synthetic resin,composite materials, metals, foil, combinations thereof, etc.) and couldinclude a printable layer backed by a substrate. The printable sheet 12is illustrated printed, however, the sheet 12 need not be printed.

As shown in FIG. 3, the magnetic sheet 14 includes a top printable layer30, an intermediate adhesive layer 32, and a bottom magnetic layer 34.The layers 30,32,34 are joined in registry to present a rectangularsheet 14 with a complemental width dimension to correspond to the sheet12. In this manner, when the sheets 12,14 are joined, the continuousprintable surface 24 defined thereby, presents a generally uniformrectangular shape adapted to be printed in most conventional printsystems. In more detail, the top printable layer 30 includes a frontface 30 a and an opposite rear face 30 b. The front face 30 a comprisesthe lower portion of the printable surface 24. The illustrated printablelayer 30 is formed of vinyl. However, the printable layer could beformed of any printable material (e.g., paper, synthetic resin, otherprintable stock, etc.). The rear face 30 b of the printable layer 30 isadhered to the magnetic layer by the intermediate adhesive layer 32. Theadhesive layer 32 preferably permanently bonds the printable layer 30 tothe magnetic layer 34 in registry. The adhesive layer 32 could be anyconventional adhesive that provides sufficient adherence between thelayers 30,34, such as a pressure sensitive adhesive. However, theadhesive could be any suitable adhesive known in the art, includingrepositionable adhesives. The bottom magnetic layer 34 includes a frontface 34 a and an opposite rear face 34 b. The front face 34 a is adheredto the printable layer 30 by the adhesive layer 32. As described indetail below, the rear face 34 b receives an applied coating carrier.The magnetic layer 34 is preferably formed of a flexible magneticmaterial having a relatively thin configuration yet still providingsufficient magnetic flux to adhere to most ferromagnetic surfaces. Forexample, the magnetic layer 34 could be formed of a ferrite powderbonded with rubber in one manner well known in the art. Although thesheet 14 is preferably magnetic, it is within the ambit of the presentinvention to utilize virtually any substrate to support one or bothsections of the printable surface 24, and the principles of the presentinvention are not limited to joining two substrates into a continuoussheet, but could also include joining more than two substrates.

Turning to FIGS. 2 and 3, the illustrated sheets 12, 14 are joined in anedge-to-edge relationship to form the seam 16 and married together withthe tape 18 to present the printable surface 24. In more detail, the topprintable surface 26 of the sheet 12 and the front face 30 a of the toplayer 30 of the sheet 14 are aligned in the same plane to present thecontinuous printable surface 24. That is to say, the sheets 12,14 do notoverlap one another. In this regard, the sheets 12,14 must be alignedwith sufficient precision to provide a relatively tight seam 16 withoutproviding any overlap between the sheets 12,14. The gap between theedges of the sheets 12,14 at the seam 16 is preferably less thanone-sixty-fourths inch and most preferably about one-one-hundredths inchor less. In this manner, the resulting business form product 10 presentsa streamline configuration having a smooth printable surface 24 andwithout a bulging seam, even when using a relatively thick substratesuch as the sheet 14. This streamline configuration enables the businessform product 10 to be stacked up with other like forms and individuallyand sequentially fed through a desktop printer.

Turning to FIGS. 4 and 5, the illustrated sheets 12,14 are joined in aweb-type inline rotary press 36, as is commonly used in various printingtechnologies including, but not limited to, flexographic or rotogravureprinting applications, that has been modified with the inventivemodifications of the present invention. In more detail, the sheet 12starts out as an upper continuous web 38 wound onto a roll 38 a. Theroll 38 a is unwound at a first unwinding station 40 including aplurality of idler rollers 42, 44, 46, 48 and 50. The unwinding stationfurther includes a web guide 52. In one manner well known in the art,the web guide 52 is an optic-type web guide that senses the alignment ofthe web 38 and communicates with the adjustable idler rollers 46,48 tocontrol adjustment of the rollers 46,48 (e.g., pivots the rollers abouta vertical axis) to effect the desired alignment. The web guide 52preferably aligns the web 38 within a tolerance of one-thirty-secondsinch. One suitable web guide is available as a special order (e.g.,configured for the specific thickness and the width of the web 38) fromCoast Controls Inc. of Sarasota, Fla. The web 38 is fed from theunwinding station 40 into a pair of nip rollers 54 and 56 where it ismarried with the sheet 14 as detailed below. The web 38 generallytravels along a longitudinal path traveling left-to-right as viewed inFIG. 4 through the nip rollers 54,56, although the web 38 movesvertically at times as it weaves through the idler rollers 44,50.

The sheet 14 starts out as a lower continuous substrate web 58 woundonto a roll 58 a. The roll 58 a is unwound at a second unwinding station60 including a plurality of idler rollers 62, 64, 66 and 68. The secondunwinding station 60 further includes a web guide 70 similar to thepreviously described web guide 52 and configured for aligning themagnetic substrate 58. The web 58 is fed from the second unwindingstation 60 into the nip rollers 54,56 where it is joined with the web 38as detailed below. Once the web 58 enters the nip rollers 54,56, thewebs 38,58 travel along the same path. Prior to entering the nip rollers54,56, the web 58 is positioned vertically below the web 38, but alsogenerally travels along a longitudinal path traveling left-to-right asviewed in FIG. 4. However, the webs 38,58 could be variously positionedprior to entering the nip rollers 54,56 (e.g., side-by-side, etc.). Itis important, however, that the webs 38,58 be sufficiently aligned whenthey enter the nip rollers 54,56 as detailed below.

In this regard, in addition to the alignment provided by the web guide70, the web 58 is further aligned by a mechanical web guide 72 prior toentering the nip rollers 54,56. In more detail, and as shown in FIG. 5,the mechanical web guide 72 includes a shaft 74 fixed to the press 36and a roller 76 rotatably supported on the shaft 74. In this regard, theroller 76 is journaled to the shaft 74 by bearings 78 press fit betweenthe shaft 74 and the roller 76. The illustrated roller 76 is a four inchouter diameter roller and one suitable bearing is available as Part No.ER16K-MHFF from MB Manufacturing Incorporated of Valparaiso, Ind. Theroller 76 is preferably formed of a machined metal, such as aluminum,and defines a generally cylindrical shape presenting a smooth outercircumferential surface 76 a. The illustrated roller 76 includes a pairof spaced apart collars 80 and 82, each being adjustably fixed to thesurface 76 a and projecting radially therefrom. For example, the collars80,82 could be fixed to the surface 76 a with set screws (not shown),such as brass-tipped, plastic-tipped, etc. The collars 80,82 are spacedapart to define a sleeve section 84 therebetween for receiving the web58. Each of the collars 80,82 presents an inside flange 80 a and 82 a,respectively, that engages the sleeve section 84 and projects radiallytherefrom to guide, and thereby align, the web 58 when the web 58engages the flange 80 a,82 a.

The illustrated flanges 80 a,82 a extend sufficiently from the surface76 a to guide the web 58 without allowing the web 58 to work over theflange 80 a,82 a and without interfering with other equipment on thepress 36. In this regard, the web 58 includes a magnetic substrate andaccordingly the flanges 80 a,82 a preferably extend about three-eighthsinch from the surface 76 a. However, in addition to the thickness of theweb that is carried, the height of the flanges 80 a,82 a is alsodependent on the spacing of the guide 72 from the closest, precedingupstream idler roller. That is to say, the closer the preceding rolleris to the guide 72, the more resistant the web 58 is to being guided andthus the web 58 is more likely to work its way over the flange 80 a,82 aor become undesirably deformed on its edges. In addition, the closer theguide 72 gets to the nip rollers 54,56, the more precise the alignmentprovided thereby becomes. In this regard, the guide 72 is preferably atleast four feet of lineal web length from the idler roller 68, morepreferably at least ten feet of web length from the roller 68, and mostpreferably about fifteen feet from the roller 68. In addition, the guide72 is preferably within one foot of lineal web length from the niproller 54 and most preferably within nine inches of the nip roller 54.

The web 58 is unwound from the roll 58 a and fed through the idlerrollers 62,64,66,68 where it is initially aligned by the web guide 70.After exiting the web guide 70, the web 58 extends along the path andengages the sleeve section 84 of the roller 76 prior to entering the niprollers 54,56. The illustrated roller 76 is a freely rotating roller,therefore, when the web 58 engages the sleeve section 84, thisengagement causes the roller 76 to rotate at the rate of feed of the web58. The collars 80,82 are preferably positioned so that in optimalalignment conditions, the web 58 does not engage either of the flanges80 a,82 a and enters the nip rollers 54,56 exactly engaging, but notoverlapping, the web 38. That is to say, at optimum alignment, therewould be virtually no gap between the webs 38,58 at the seam 16.However, given the tendencies of the optic-type guide 70 to loop the web58, optimum alignment will not always be achieved. When not in optimumalignment, the web 58 will engage either the flange 80 a or the flange82 a. When the web 58 engages one of the flanges 80 a,82 a, the web 58is caused to move back into the sleeve section 84, i.e., back intooptimum alignment. As the web 58 adjusts, there will be slighttolerances associated with the adjustment. With the most preferredconfiguration described above, the mechanical web guide 72 can enablealignment of the web 58 within one-one-hundredths inch of the web 38.

The illustrated mechanical web guide 72 enables the webs 58,38 to beprecisely aligned in the edge-to-edge relationship. In addition, theroller 76 presents smooth rotating surfaces that engage the web 58 thusreducing the risk of undesired damage to the web 58 resulting fromfriction between the web 58 and the roller 76. This is particularly soin the illustrated roller 76 wherein the entire roller 76 rotates at therate of feed of the web 58. However, it is within the ambit of thepresent invention to utilize various alternative configurations for themechanical web guide 72. For example, the mechanical web guide couldutilize a single collar and flange, particularly when used to alignsubstrates such as paper where only one good edge may be presented.Additionally, the collar or collars could be stationary with only thesleeve section rotatable. Alternatively, the entire guide could beforcibly driven to rotate at the rate of feed of the corresponding web.However, it is important that at least a portion of the web guide engagethe web and be rotatable (e.g., the sleeve, the collar, or the entireroller, etc.). It is within the ambit of the present invention toutilize one or more mechanical web guides to align one or more of thewebs, however, it is important that whatever mechanical web guides areutilized be positioned to facilitate alignment and reduce the risk ofundesired damage to the web or webs.

Once the webs 38,58 are aligned, they are joined together by applyingthe heat-resistant tape 18 over the seam 16. In more detail, the tape 18starts out as a continuous streamer of tape 86 wound around a spool 86a. The streamer 86 is unwound, aligned over the seam 16, and appliedalong the seam 16 at a tape-applying station 88. The tape-applyingstation 88 includes the previously described nip rollers 54,56, a firsttape guide 90, and a second tape guide 92. The first tape guide 90 is arough guide to facilitate unspooling the streamer 86. The illustratedguide 90 is a simple eye-bolt fixed relative to the press 36. The secondtape guide 92 is a mechanical tape guide for aligning the streamer 86over the seam 16. Particularly, the guide 92 includes a shaft 94 fixedrelative to the press 36 and a roller 96 rotatably supported on theshaft 94. The guide 92 is sized and dimensioned differently than thepreviously described guide 72, but is similar thereto in many respects.The roller 96 is journaled to the shaft 94 by bearings 98 press fitbetween the shaft 94 and the roller 96. The illustrated roller 96 is aone and one-quarter inch outer diameter roller and one suitable bearingis available as Part No. 6001-2Z from SKF of Kulpsville, Pa. The roller96 is preferably formed of a machined metal, such as aluminum, anddefines a generally cylindrical shape presenting a smooth outercircumferential surface 96 a. The illustrated roller 96 includes a pairof spaced apart collars 100 and 102, each being adjustably fixed to thesurface 96 a and projecting radially therefrom. For example, the collars100,102 could be fixed to the surface 96 a with set screws (not shown),such as brass-tipped, plastic-tipped, etc. The collars 100,102 arespaced apart to define a sleeve section 104 therebetween sized anddimensioned for receiving the streamer 86. Each of the collars 100,102presents an inside flange 100 a and 102 a, respectively, that engagesthe sleeve section 104 and projects radially therefrom to guide, andthereby align, the streamer 86 when the streamer 86 engages the flange100 a,102 a.

As shown in FIG. 5, the mechanical tape guide 92 aligns the streamer oftape 86 over the seam 16 prior to the streamer 86 entering the niprollers 54,56. Once the streamer 86 enters the nip rollers 54,56, thestreamer 86 is applied to the webs 38,58 over and along the seam 16 tothereby marry the webs 38,58 into a single continuous sheet 106. Theseam 16 extends along and is generally parallel to the longitudinal pathof the press 36. Similar to the web guide 72 discussed above, theillustrated tape guides 90,92 are configured and positioned to provideoptimum alignment of the streamer 86 over the seam 16 withoutundesirably deforming the streamer 86 or interfering with any otherpress equipment. In this regard, the mechanical tape guide 92 preferablyhas a flange height of at least three-thirty-seconds inch and mostpreferably between one-eighth and three-sixteenths inch. The guide 92 ispreferably within one foot of lineal streamer length of the nip roller54 and most preferably within three inches thereof. The rough guide 90is preferably at least about two feet from the spool 86 a and preferablybetween six and nine inches from the guide 92. However, just asdiscussed above with respect to the guide 72, the guide 92 could bealternatively configured and positioned.

As shown in FIG. 4, the single continuous sheet 106 is fed over an idlerroller 108 and wound into a roll 106 a. The roll 106 a of the continuoussheet 106 is a business form product as that phrase is used herein,whether the sheet 106 has been printed or not. Although not shown inFIG. 4, once the tape 86 has been applied, the continuous sheet 106 canbe fed into other downstream stations, such as a station for applying acoating carrier 108. The use of the coating carrier 108 is preferredwith the magnetic substrate, particularly if the magnetic substrate isdie cut. The coating carrier 108 is applied to the rear face 34 b of themagnetic layer 34 of the sheet 14, i.e. to the rear face of the web 58.The coating carrier 108 retains the magnetic sheet 14 together after thesheet 14 has been die cut and enables the sheet 14 to be easily andquickly removed from a stack of other similar magnetic sheets (e.g., forsequential feeding into an offline print system, etc.) withoutinhibiting the desired magnetic properties of the finished business formproduct 10. One suitable coating carrier is disclosed in the '735Application previously incorporated herein by reference. As described inthe '735 Application, the press 36 could be readily modified by thoseskilled in the art to apply the coating carrier 108.

As previously indicated, the coating carrier 108 retains the magneticsheet 14 and/or the web 58 together after the sheet 14 or web 58 hasbeen die cut, yet allows the die cut portion to be quickly and easilyremoved from the sheet 14. In the illustrated business form product 10,a pair of cards 110 and 112 are formed in the magnetic sheet 14 by aplurality of die cuts 114 formed in the magnetic sheet 14 (see FIGS. 1and 3). Similar cards are described in detail in the '735 Applicationpreviously incorporated herein. The plurality of die cuts 114 can bemade at a downstream station in the press 36 (not shown) once thecontinuous sheet 106 has been formed, or can be done in a separate pressafter the sheet 106 has been rolled in the roll 106 a.

In order to convert the continuous sheet 106 into the illustratedbusiness form product 10, the sheet 106 is simply sheeted to the desiredlength and printed. The sheeting can be done in the press 36, such as inan exit station (not shown) where the sheet 106 is sheeted to thedesired length and die cut to form the die cuts 114. Alternatively, thesheet 106 can be rolled into the roll 106 a and transferred to anotherpress where the sheeting is done. The individual business form productscan then be stacked and taken offline to a separate print station (e.g.,a desktop laser or ink jet printer) to form the finished business formproduct 10. However, the continuous sheet 106 could also be printedinline in the press 36 at one or more print stations (not shown) in anymanner known in the art. As shown in FIG. 7, in the preferred embodimentof sheeting and printing the products to provide a finished businessform product 10, the method involves the steps of feeding a firstcontinuous substrate web 300, feeding a second continuous substrate web302, aligning the first and second webs to form a seam therebetween 304,applying a continuous streamer of tape to the webs over and along theseam 306, sheeting the continuous sheet into individual forms 308, andprinting at least one of the individual forms in a laser printer 310.

As indicated above, when the sheets 12,14 are joined, the continuousprintable surface 24 defined thereby, presents a generally uniformrectangular shape adapted to be printed in most conventional printstations. For example, the illustrated printable surface 24 presented bythe business form product 10 preferably has conventionaleight-and-one-half by eleven inch margins to enable the product 10 to beprinted in conventional desktop print systems such as laser or ink jetprinters. However, it is within the ambit of the present invention toconfigure and dimension the business form product 10 for virtually anyprinting application, including, but not limited to, larger productionrun print systems such as web-type, flexographic printing applicationswherein product dimensions are virtually unlimited.

As previously indicated, the tape 18, and thus the streamer of tape 86,is heat-resistant tape. In this regard, the tape 18 can be fed through ahigh heat print station, such as a laser printer, and maintain thejoinder of the seam 16 without degrading or fracturing the seam 16. Theterm heat-resistant tape, as that term is used herein, refers to a tapethat maintains its adhesive integrity when exposed to temperatures ashigh as one-hundred, seventy-five degrees Fahrenheit. Referring back toFIGS. 2 and 3, the illustrated tape 18 includes a backing layer 116 andan adhesive layer 118. The illustrated backing layer 116 is formed frompolyester. In this regard, it is important that the backing layer 116 beat least primarily formed from polyester in order to provide the desiredheat-resistant qualities and in order to enable a streamline profile forthe tape seam 18. That is to say, a primarily paper backing, even ifthick enough to provide the necessary strength, is not preferred becauseof its relative thickness. The illustrated adhesive 118 is a solventrubber resin adhesive. One suitable tape is available as Model No. 18-RMfrom International Tape Company of Windham, N.H. However, variousalternative adhesives could be utilized. For example, the adhesive couldbe a UV cured pressure-sensitive adhesive or an acrylic adhesive.However, it is important that the tape be heat-resistant as that term isused herein and provide for a relatively low-profile, streamlined tapeseam. In this manner, the business form product 10 can be printed inhigh heat print applications, such as a laser printer.

As previously indicated, the multiple webs, or substrates, joined by themethod of the present invention are not limited to any particular typeof substrate or relative thickness, so long as the multiple webs arejoined in an edge-to-edge relationship. One such suitable alternativeembodiment is the business form product 200 illustrated in FIG. 6. Thebusiness form product 200, similar to the previously described businessform product 10, is formed by joining multiple substrates 202 and 204 inan edge-to-edge relationship to form a seam 206 therebetween andmarrying the substrates 202,204 by applying a heat-resistant tape 208over and along the seam 206. The illustrated substrate 202 is formedfrom paper and the illustrated substrate 204 is formed from plastic.However, the substrates could be formed from virtually any materialsuitable for printing applications. The business form product 200 isshown in section and thus could be either a continuous sheet, similar tothe continuous sheet 106 detailed above formed in the press 36, or anindividual form sheeted from the continuous sheet.

The preferred forms of the invention described above are to be used asillustration only, and should not be utilized in a limiting sense ininterpreting the scope of the present invention. Obvious modificationsto the exemplary embodiments, as hereinabove set forth, could be readilymade by those skilled in the art without departing from the spirit ofthe present invention.

The inventor hereby states his intent to rely on the Doctrine ofEquivalents to determine and assess the reasonably fair scope of thepresent invention as pertains to any apparatus not materially departingfrom but outside the literal scope of the invention as set forth in thefollowing claims.

1. A method of forming a business form product of multiple substrates,said method comprising the steps of: (a) feeding a first continuoussubstrate web along a longitudinal path; (b) feeding a second continuoussubstrate web along the path; (c) aligning the first and second webs ina non-overlapping edge-to-edge relationship to form a seam therebetween,wherein the seam extends along and is at least generally parallel to thepath, with any spacing between the webs along the seam being from zeroto less than one-sixty-fourths of an inch; and (d) applying a continuousstreamer of heat resistant tape to the webs over and along the seam toretain the webs in said edge-to-edge relationship to thereby form acommon continuous sheet.
 2. The method as claimed in claim 1, one ofsaid webs being at least in part formed from magnetic material.
 3. Themethod as claimed in claim 1, step (c) including the step of placing thefirst and second webs in contact with each other along at least part ofthe seam.
 4. The method as claimed in claim 1, said longitudinal pathbeing defined in a rotary press; and (e) feeding said continuous sheetthrough the press.
 5. The method as claimed in claim 1; and (e) rollingthe continuous sheet into a roll to thereby form the business formproduct.
 6. The method as claimed in claim 1; and (e) sheeting thecontinuous sheet into individual forms to thereby form the business formproduct.
 7. The method as claimed in claim 6; and (f) printing at leastone of said individual forms in a laser printer without fracturing theseam.
 8. The method as claimed in claim 1; and (e) feeding at least aportion of said continuous sheet through a laser printer including aheat source between the ranges of one-hundred and one-hundred andseventy-five degrees Fahrenheit, said heat-resistant tape being operableto substantially retain the webs in said edge-to-edge relationship afterbeing exposed to said heat source.
 9. The method as claimed in claim 1,said streamer of tape including a backing layer and an adhesive.
 10. Themethod as claimed in claim 9, said backing layer being formed frompolyester.
 11. The method as claimed in claim 10, said adhesive being anultraviolet-cured pressure sensitive adhesive.
 12. The method as claimedin claim 10, said adhesive being formed from acrylic.
 13. The method asclaimed in claim 10, said adhesive being formed from rubber.
 14. Themethod as claimed in claim 1, said longitudinal path being defined in arotary press, step (d) including the step of feeding the aligned websand the streamer of tape through a nip roller to apply the tape over andalong the seam.
 15. The method as claimed in claim 14, step (c)including the steps of aligning at least one of the webs with amechanical guide prior to feeding the at least one web through the niproller.
 16. The method as claimed in claim 15, said mechanical guideincluding a shaft and at least one collar that engages one edge of theat least one web to thereby align said at least one web in saidedge-to-edge relationship with the other web, said at least one webbeing within at least about one-one-hundredths of an inch from saidother web when in said edge-to-edge relationship.
 17. The method asclaimed in claim 16, said mechanical guide being positioned upstream ofthe nip roller and located within one foot of web length from the niproller.
 18. The method as claimed in claim 17, said at least one webbeing at least in part formed from magnetic material, step (c) furtherincluding the step of feeding the at least one web through an idlerroller prior to feeding the at least one web through said mechanicalguide, said idler roller being positioned at least four feet of weblength from the mechanical guide.
 19. The method as claimed in claim 14,step (d) further including the step of feeding the streamer of tapethrough at least one mechanical guide prior to feeding the tape throughthe nip roller.
 20. The method as claimed in claim 19, said at least onemechanical guide including a stationary shaft and a collar rotatablysupported on the shaft, said collar operable to engage both opposededges of the streamer of tape to align the streamer of tape over theseam.
 21. The method as claimed in claim 20, said at least onemechanical guide being positioned about three inches of streamer lengthfrom the nip roller.
 22. The method as claimed in claim 20, step (d)further including the step of feeding the streamer of tape through anadditional mechanical guide prior to feeding the tape through saidfirst-mentioned mechanical guide, said additional mechanical guideincluding an eyelet that the streamer of tape passes through.
 23. Themethod as claimed in claim 22, said additional mechanical guide beingpositioned between six and nine inches of streamer length from saidfirst-mentioned mechanical guide, said additional mechanical guide beingat least about two feet of streamer length from any other upstreamroller.
 24. A printable business form product that comprises multiplesubstrates and is formed by a process comprising the steps of: (a)feeding a first continuous substrate web along a longitudinal path; (b)feeding a second continuous substrate web along the path; (c) aligningthe first and second webs in a non-overlapping edge-to-edge relationshipto form a seam therebetween, wherein the seam extends along and is atleast generally parallel to the path, with any spacing between the websalong the seam being from zero to less than one-sixty-fourths of aninch; and (d) applying a continuous streamer of heat resistant tape tothe webs over and along the seam to retain the webs in said edge-to-edgerelationship to thereby form a common continuous sheet.
 25. The businessform product as claimed in claim 24, one of said webs being at least inpart formed from magnetic material.
 26. The business form product asclaimed in claim 24, step (c) including the step of placing the firstand second webs in contact with each other along at least part of theseam.
 27. The business form product as claimed in claim 24, saidlongitudinal path being defined in a rotary press; and (e) feeding saidcontinuous sheet through the press.
 28. The business form product asclaimed in claim 24; and (e) rolling the continuous sheet into a roll tothereby form the business form product.
 29. The business form product asclaimed in claim 24; and (e) sheeting the continuous sheet intoindividual forms to thereby form the business form product.
 30. Thebusiness form product as claimed in claim 29; and (f) printing at leastone of said individual forms in a laser printer without fracturing theseam.
 31. The business form product as claimed in claim 24; and (e)feeding at least a portion of said continuous sheet through a laserprinter including a heat source between the ranges of one-hundred andone-hundred and seventy-five degrees Fahrenheit, said heat-resistanttape being operable to substantially retain the webs in saidedge-to-edge relationship after being exposed to said heat source. 32.The business form product as claimed in claim 24, said streamer of tapeincluding a backing layer and an adhesive.
 33. The business form productas claimed in claim 32, said backing layer being formed from polyester.34. The business form product as claimed in claim 33, said adhesivebeing an ultraviolet-cured pressure sensitive adhesive.
 35. The businessform product as claimed in claim 33, said adhesive being formed fromacrylic.
 36. The business form product as claimed in claim 33, saidadhesive being formed from rubber.
 37. The business form product asclaimed in claim 24, said longitudinal path being defined in a rotarypress, step (d) including the step of feeding the aligned webs and thestreamer of tape through a nip roller to apply the tape over and alongthe seam.
 38. The business form product as claimed in claim 37, step (c)including the steps of aligning at least one of the webs with amechanical guide prior to feeding the at least one web through the niproller.
 39. The business form product as claimed in claim 38, saidmechanical guide including a shaft and at least one collar that engagesone edge of the at least one web to thereby align said at least one webin said edge-to-edge relationship with the other web, said at least oneweb being within at least about one-one-hundredths of an inch from saidother web when in said edge-to-edge relationship.
 40. The business formproduct as claimed in claim 39, said mechanical guide being positionedupstream of the nip roller and located within one foot of web lengthfrom the nip roller.
 41. The business form product as claimed in claim40, said at least one web being at least in part formed from magneticmaterial, step (c) further including the step of feeding the at leastone web through an idler roller prior to feeding the at least one webthrough said mechanical guide, said idler roller being positioned atleast four feet of web length from the mechanical guide.
 42. Thebusiness form product as claimed in claim 37, step (d) further includingthe step of feeding the streamer of tape through at least one mechanicalguide prior to feeding the tape through the nip roller.
 43. The businessform product as claimed in claim 42, said at least one mechanical guideincluding a stationary shaft and a collar rotatably supported on theshaft, said collar operable to engage both opposed edges of the streamerof tape to align the streamer of tape over the seam.
 44. The businessform product as claimed in claim 43, said at least one mechanical guidebeing positioned about three inches of streamer length from the niproller.
 45. The business form product as claimed in claim 43, step (d)further including the step of feeding the streamer of tape through anadditional mechanical guide prior to feeding the tape through saidfirst-mentioned mechanical guide, said additional mechanical guideincluding an eyelet that the streamer of tape passes through.
 46. Thebusiness form product as claimed in claim 45, said additional mechanicalguide being positioned between six and nine inches of streamer lengthfrom said first-mentioned mechanical guide, said additional mechanicalguide being at least about two feet of streamer length from any otherupstream roller.
 47. A printable blank comprising: a first portionformed from a first web; a second portion formed from a second web, saidfirst portion being positioned in a non-overlapping edge-to-edgerelationship with said second portion to define a seam therebetween,with any spacing between the portions along the seam being from zero toless than one-sixty-fourths of an inch; and tape retaining said firstand second portions in said edge-to-edge relationship, said tape beingaffixed to said first and second portions and thereby overlying saidseam, said tape being heat resistant.
 48. The blank as claimed in claim47, said first and second webs being positioned in contact with eachother along at least part of the seam.
 49. The blank as claimed in claim47, said tape substantially retaining said first and second portions insaid edge-to-edge relationship at all ambient temperatures between theranges of one-hundred and one-hundred and seventy-five degreesFahrenheit.
 50. The blank as claimed in claim 49, said tape including abacking layer and an adhesive.
 51. The blank as claimed in claim 50,said backing layer being formed from polyester.
 52. The blank as claimedin claim 51, said adhesive being an ultraviolet-cured pressure sensitiveadhesive.
 53. The blank as claimed in claim 51, said adhesive beingformed from acrylic.
 54. The blank as claimed in claim 51, said adhesivebeing formed from rubber.
 55. The blank as claimed in claim 47, saidfirst portion being formed of paper.
 56. The blank as claimed in claim47, said first portion being formed of a nonmagnetic material, saidsecond portion being at least in part formed of a magnetic material. 57.The blank as claimed in claim 56, said second portion including a topprintable layer and a bottom magnetic layer.